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Precision Metal Stamping Assembly Services

IATF 16949 certified workflows for precision metal stamped parts feed directly into our integrated high-speed assembly lines for Tier 1 and OEM manufacturers in automotive, EV, medical, and appliances sectors. By uniting custom progressive die tooling with automated in-die assembly, precision resistance/laser welding, riveting, and hardware staking, we reduce supply chain complexity and deliver certified, zero-defect sub-assemblies ready for immediate line integration.

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  • IATF 16949 & ISO 9001
  • In-Die & Secondary Joining
  • 100% Inline AOI
  • In-House Toolroom · DFM
  • CRITICAL PRODUCTION RISKS

    Preventing Complex Bottlenecks in Metal Stamping Assembly

    Integrating high-speed metal stamping with secondary joining operations requires absolute precision. Subtle variations in metal temper, micro-burrs, or fixture wear can cascade into catastrophic assembly failures during mass production.

    • Tolerance Stack-Up & Structural Stress Fissures

      When combining multiple stamped components with hardware or plastic inserts, minor dimensional variations accumulate rapidly. Uncontrolled springback in high-tensile alloys or improper press-fit interference causes pitch misalignment, plastic body cracking during insert injection, or premature mechanical failure under dynamic vibration.

      Consequence: Severe scrap spikes during downstream line integration, costly emergency tool modifications, and systemic structural failures that violate stringent metal stamping assembly and quality benchmarks.

    • Inconsistent Joining Integrity in Secondary Automation

      Automated riveting, staking, and spot welding demand exact part positioning and pristine contact surfaces. Residual stamping lubricants, oxidized plating, or micro-burrs introduce localized resistance spikes—resulting in weak cold welds, skewed threaded studs, or elevated contact resistance above 50 mΩ across electrical joints.

      Consequence: Intermittent electrical open-circuit failures or sudden mechanical joint separation under operating torque, forcing costly line shutdowns and complex troubleshooting for high-density components.

    • Unnoticed Defect Escapes in High-Speed Assembly

      In high-speed production running above 200 SPM, critical micro-defects—such as missed tapped threads, shallow hardware insertion depth, or internal plating flaking—are impossible to catch via manual inspection. Without real-time inline optical or torque sensing, a single defective batch can pollute entire inventory lots.

      Consequence: Mass containment actions, compromised end-product reliability, and critical supplier audit failures under strict IATF 16949 quality management standards.

    Don’t let manufacturing risks derail your project. You don’t just need a supplier who can run a machine; you need an engineering partner who masters the complex science of precision Assembly Services art.

    OPERATIONAL SYNERGY

    Why Choose Kravzik as Your Integrated Stamping & Assembly Partner

    Eliminate multi-vendor friction, reduce quality risks, and accelerate time-to-market. Kravzik combines simulation-driven engineering, automated in-die assembly, and 100% inline inspection under one roof—delivering certified, production-ready metal sub-assemblies.

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    Early Risk Mitigation & DFM Engineering

    Eliminate assembly bottlenecks and costly tool rework before tool steel is cut. Our in-house progressive die tooling team leverages advanced Siemens NX 3D simulation to analyze stress paths, springback, and tolerance stack-ups across complex multi-part assemblies.

    Predictive Springback & Pitch Optimization: Simulates dynamic strip behavior to prevent cumulative pitch drift and material thinning.

    Co-Engineered Assembly Design: Recommends part geometries that optimize press-fit interference and automated welding accessibility.

    In-House Tooling Precision: Fabricates multi-station progressive dies using Wire EDM and profile grinding within ±0.002 mm tolerances.

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    High-Throughput Automated Assembly

    Consolidate complex manufacturing steps into a single seamless, cost-effective operation. Our high-speed progressive die stamping lines integrate automated hardware insertion, tapping, riveting, and resistance welding to maximize production throughput.

    In-Die Fastener & Terminal Insertion: Automatically feeds and stakes threaded studs, nuts, and compliant press-fit pins inside the active die.

    Multi-Process Joining Operations: Executes automated spot welding, laser welding, and mechanical clinching for multi-metal sub-assemblies.

    Hybrid & Insert Molding Synergy: Integrates stamped busbars and electrical terminals into continuous overmolding and insert molding operations.

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    Zero-Defect Quality Assurance

    Achieve zero-defect quality across high-speed production runs. Our presses feature integrated in-die contact sensors and continuous high-speed camera systems to verify critical assembly features in real time without sacrificing press speed.

    100% In-Line AOI Vision Verification: Instantly checks hardware presence, thread presence, bend radii, and co-planarity at full press speed.

    In-Die Sensor Tool Protection: Detects misfeeds, short hits, or double-sheet loads within milliseconds to protect tooling and guarantee part integrity.

    Backed by Zeiss CMMs and OGP smart scopes under strict IATF 16949 quality management standards with full batch traceability.

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    Turnkey Single-Source Supply Chain

    Simplify vendor logistics, reduce management overhead, and shorten program launch timelines. Kravzik manages raw material sourcing, precision stamping, secondary joining, plating, and tactical scheduling as a unified, turnkey service. Learn how our one-stop metal assemblies approach eliminates multi-vendor complexity for Tier 1 manufacturers.

    Manages selective precious metal plating, e-coating, and passivation through our in-house industrial surface finishing capabilities without multi-vendor handoffs.

    Full Material & Process Traceability: Complete batch control and automated Cpk monitoring with Cpk ≥ 1.33 for critical dimensional parameters.

    Turnkey Secondary Operations: Provides complete assembly, packaging, and reeled part delivery tailored for automated customer production lines.

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    MANUFACTURING ARCHITECTURE

    Precision Multi-Component Stamping & Joining Solutions

    Streamline your supply chain by converting complex multi-step sub-assemblies into a single automated line. Kravzik integrates in-die hardware staking, automated welding, and continuous quality monitoring to produce production-ready metal assemblies.

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      In-Die Hardware Staking & Fastener Insertion

      Eliminate labor-intensive secondary operations. Our active tooling systems automatically feed, align, and press-fit secondary hardware directly inside the dynamic stamping stroke with repeatable positional precision.

      Automated Hardware Feeding: In-die insertion of threaded studs, nuts, bushings, and compliant press-fit pins (Eye-of-the-Needle) at production press speeds.
      Inline Tapping & Threading: High-speed mechanical and servo-driven in-die tapping to create internal threads without multi-station transfer.
      Retention Force Guarantee: Precision coining and staking features optimized to meet stringent torque-out and push-out resistance specifications.
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      Automated Multi-Metal Joining & Welding

      Join dissimilar metals and delicate contact materials with consistent mechanical and electrical integrity. We deploy both thermal and mechanical bonding techniques tailored to your product geometry.

      Resistance & Spot Welding Integration: Automated inline welding for bimetal contacts, lead frames, and heavy-gauge conductive strips.
      Mechanical Clinching & TOX Joining: Fastener-free mechanical interlocking for coated, pre-plated, or un-weldable multi-layer metal sheet combinations.
      Laser & EB Welding Support: High-precision energy beam joining for leak-tight and low-resistance electrical connections on critical sub-assemblies.
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      Insert Molding & Substrate Synergy

      Bridge the gap between metal stamping and polymer molding. We engineer stamped electrical terminals and custom components optimized for downstream or continuous reel-to-reel plastic overmolding.

      Stamped Busbar Integration: Manufacturing high-current busbars with tailored lead geometry and surface activation for PEEK/PBT overmolding.
      Compliant Terminal Alignments: Stamping stamped electrical terminals with tight pitch control to ensure accurate seating in automated insert molding cavities.
      Selective Plating Protection: Protecting critical contact zones and precious metal inlays from damage during secondary assembly operations.
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      Assembly-Specific Quality & Force Verification

      Prevent un-assembled, misaligned, or structurally weak components from reaching your line. Our quality framework validates mechanical strength and component presence in real time.

      100% In-Die Hardware Detection: Contact sensors and optical proximity switches check for part presence and proper seating depth before every stroke.
      Inline CCD Assembly Inspection: High-speed camera vision systems continuously audit orientation, crimp heights, and thread integrity at 100% line speed.
      Push-Out & Torque Destructive Testing: Automated SPC push-out force verification backed by certified IATF 16949 quality management protocols.
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    Quality Control for Precision Stamping & Integrated Assembly

    We secure long-term structural and electrical reliability for your multi-part metal assemblies through rigorous, data-driven process control. Operating under a certified IATF 16949 quality management system, we combine automated inline vision inspection, automated joining, and real-time in-die monitoring to guarantee zero-defect precision down to ±0.01mm across high-speed stamping and assembly operations.

    In-Die Assembly
    In-Die Tapping
    Automated In-Die Riveting
    Resistance & Laser Welding
    Precious Metal Plating
    Reel-to-Reel Packaging
    In-Line Vision Inspection
    Multi-Material Joining
    MANUFACTURING ARCHITECTURE

    Precision Metal Stamping & Assembly Capabilities

    Engineered to satisfy the stringent quality standards of medical devices, EV powertrains, and precision electronics. We transform complex engineering requirements into production-ready stamped components and high-speed in-die assemblies.

    • Precision Terminals, Pins & Electrical Contacts

      High-speed, tight-tolerance stamping for critical electrical interconnects and signal transmission in telecom and electronics. We utilize advanced wire EDM tooling, selective precious metal plating, and automated bandolier packaging to ensure absolute coplanarity and flawless conductivity.

      Key Components

      Reel-Fed Bandolier Terminals, Press-Fit Pins (Eye-of-the-Needle), Wire & Cable Crimps, Selective-Plated Blade Terminals, Micro-Miniature Socket Contacts, Tuning Forks, Medical Sensor Contacts

    • Lead Frames, Sensor Housings & Micro-Components

      Ultra-precision micro-stamping for semiconductor packaging and specialized medical diagnostics. Formed with strict burr control and stress-free strip handling on fragile copper alloy, titanium, and stainless steel substrates.

      Key Components

      IC Lead Frames, Selective-Plated Lead Frames, QFN/SOIC Stamped Substrates, Medical Implantable Contacts, Surgical Instrument Sensor Inserts, Fluidic Diagnostics Components

    • High-Current Busbars & Power Distribution Hardware

      Copper busbars engineered for thermal performance and high-amperage current carrying are fully integrated with automated in-die hardware insertion, tapping, and multi-metal joining to streamline complex assembly operations.

      Key Components

      Custom Copper Busbars, Flexible Laminated Shunts, Battery Interconnect Strips, High-Current Cable Lugs, Fuse Clips & Holder Terminals, Medical Power Supply Contact Rails

    • Structural Brackets, Shielding & Enclosures

      Complex mechanical enclosures, EMI/RFI shielding cans, and load-bearing structural sub-assemblies. Leveraging integrated Siemens NX 3D springback simulation and 100% inline camera inspection to guarantee zero-defect geometric accuracy.

      Key Components

      Board-Level Shielding Covers (BLS), Medical Device Structural Housings, Automotive Compression Limiters, Rolled & Crush Bushings, Heat Sinks, In-Die Staked Structural Brackets

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    MANUFACTURING CAPABILITIES

    Integrated Metal Stamping Ecosystem

    We eliminate multi-vendor friction by consolidating high-speed progressive die stamping, automated in-die hardware assembly, precision metal joining, and full supply chain management under one roof. Powered by high-performance Minster and Bruderer presses, Siemens NX DFM simulations, and active OEE monitoring, our ecosystem is custom-engineered to manufacture zero-defect sub-assemblies. From raw coil sourcing to multi-component automated joining, we deliver turnkey metal stamping assembly solutions with uncompromised accuracy and total process control.

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    High-speed press capacity means nothing without sub-micron assembly control. Operating a specialized fleet of Minster and Bruderer presses (30 to 90+ tons, up to 1,500 strokes/min), our equipment is optimized for dynamic, multi-station in-die assembly operations.

    High-Speed Assembly Press Bed: Expansive bed areas specifically designed for multi-stage progressive dies that handle simultaneous stamping, metal folding, and automated hardware feeding in a single press cycle.

    Closed-Loop OEE & Pitch Control: Active press monitoring system tracks tonnage and strip feed pitch in real time, instantly adjusting parameters to prevent misfeeds during delicate assembly operations (e.g., terminal crimping or pin insertion).

    100% In-Line Vision & Sensor Inspection: Integrated high-resolution camera systems and in-die sensors inspect 100% of assembly features—verifying thread integrity, fastener presence, and critical clearances on every stroke.

    Complex assemblies often demand joining dissimilar metals with vastly different mechanical properties. Our metallurgical expertise ensures seamless cold-forming, crimping, and welding across non-ferrous, precious, and structural alloys.

    Expert handling and selective plating for Bimetals, Copper, Beryllium Copper, Brass, Phosphor Bronze, Stainless Steel, High-Strength Steels, and Aluminum — our full <a href="http: //kravzik.com/materials/stamping-metals-alloys/”>stamping metals and alloys portfolio engineered for hybrid metal stamping.

    Dimensional Envelope for Assemblies:
    – Assembly Length / Width Range: 0.25 in (6.35 mm) to 24 in (609.6 mm)
    – Material Gage Thickness Range: 0.002 in (0.051 mm) to 0.375 in (9.5 mm)
    – Critical Mating Tolerances: Mass-production mating tolerances held strictly to ±0.001 in (±0.025 mm) across complex multi-component stacks.

    Assembling parts inside a high-speed die requires predictable material behavior. Through a “co-engineered” partnership, we simulate component interaction and stress distribution before steel is cut to guarantee reliable assembly performance.

    Siemens NX 3D Assembly Simulation: Advanced CAD modeling predicts strip springback, material flow, and interference during in-die staking, tapping, and hardware insertion to prevent assembly jam-ups.

    Rapid Prototype Validation: Utilizing Wire EDM, precision waterjet cutting, and 3D printing to supply fully functional, assembly-ready prototypes for early fit, form, and electrical/mechanical testing.

    In-House Progressive Tool Room: Dedicated toolmaker team designs, builds, and maintains multi-cavity progressive assembly tooling in-house, ensuring zero downtime and lifetime die maintenance.

    Replacing costly secondary assembly processes, we engineer high-efficiency mechanical joining, threading, and welding features directly into the stamping stroke to streamline production and slash total part costs.

    Automated In-Die Hardware Insertion: Direct high-speed feeding and staking of nuts, studs, screws, crush bushings, compression limiters, and plastic inserts onto stamped metal strips during the die stroke.

    Complex In-Die Functional Features: Fully automated in-die tapping, thread forming, compliant pin (eye-of-the-needle) production, IDC slotting, and bi-metal cold welding.

    High-Reliability Joining & Surface Operations: Secondary electron beam (EB) welding, automated spot welding, specialized heat treatment, and continuous reel-to-reel selective plating for high-conductivity electrical contacts.

    We act as a true single-source partner, managing everything from raw coil procurement and in-die production to secondary sub-assembly, quality inspection, and tactical scheduling to drastically reduce your supplier count.

    Advanced Sub-Assembly Metrology: Outfitted with Zeiss CMMs, OGP smart optical scopes, and force/displacement test systems to perform First-Article Inspection (FAIR) and retention force testing on staked hardware.

    Automotive & High-Reliability Certifications: Fully operating under IATF 16949 and ISO 9001 certified quality systems, guaranteeing total traceability for safety-critical OEM components.

    Synchronized Kitting & Reel Logistics: Customized packaging solutions—including continuous carrier tape reels, bandoliers, or returnable trays—delivering assembled components directly to your automated assembly lines on time.

    PRODUCT SHOWCASE

    Explore Our Precision Metal Stamped Parts & Custom Components

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    PRODUCT APPLICATIONS

    Industries Served

    Discover how we translate precision engineering into industry-specific success. From renewable energy to semiconductor processing, our components are tailored to meet rigorous sector standards — backed by documented case studies.

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    EV Metal Stampings

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    Plastic-Metal Stampings

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    Logistics

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    Semiconductors

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    Medical

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    Consumer Electronics

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    Aerospace

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    Defense

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    • MANUFACTURING CAPABILITIES

      Metal Stamping & Die Tooling

      Engineered for high-volume reliability and critical automotive tolerances. Leveraging our ultra-precision tooling backbone—powered by simultaneous CNC, Wire EDM, and PG grinding—we build elite high-speed progressive dies and precision compound tooling to guarantee strict ±0.01mm accuracy. Our in-house tool room designs and builds custom progressive die tooling optimized for high-volume assembly production, ensuring long die life and tight tolerances. From heavy-gauge structural brackets to intricate electrical terminals & contacts, we provide a true end-to-end stamping ecosystem. Our unique integrated manufacturing advantage seamlessly bridges pure metal stamping with advanced insert molding operations under one roof, delivering a unified, single-source solution from raw alloy selection to final surface treatment.

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    • MANUFACTURING CAPABILITIES

      Precision Metal Stamped Parts & Assemblies

      Engineered for critical conductivity and uncompromising structural integrity. As an IATF 16949 certified manufacturer, we specialize in high-volume custom precision metal stamping parts that demand strict tolerances. Powered by state-of-the-art 35T and 50T precision presses and a sub-micron in-house tooling ecosystem, we expertly process high-performance copper alloys, stainless steel, and specialty metals. Our capabilities span a comprehensive portfolio, including micro-precision electrical terminals, lead frames, robust stamped metal brackets, and EMI/RFI shields. Moving beyond standard stamping parts manufacturers, we combine these stamped metal components with seamless in-house insert molding integration, delivering true one-stop, zero-defect assemblies for your most complex engineering challenges.

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    TECHNICAL SUPPORT

    Engineering Solutions & Design Insights

    Access expert technical guidance to optimize your component designs and resolve manufacturing challenges. Our engineering resources cover critical material selection, tolerance control, and failure prevention to ensure reliable performance in your specific application.

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    Before Plating Batch: Stamped Electrical Terminals Finish Audit Checklist

    A supplier who plates your terminals but skips the JESD201 post-plating anneal will pass the incoming dimensional check. You discover tin whiskers only after field returns arrive. This checklist audits plating specification, pre-treatment protocols, and post-plating verification. Go through every item.

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    Before PPAP Submission: Stamped Electrical Terminals Compliance Audit Checklist

    A PPAP package submitted with a compliance letter but without the Cpk capability study will pass the document checklist and fail the customer SQE review. This checklist audits dimensional capability data, material cert traceability, and testing standards documentation before the submission package leaves your supplier. Go through every document.

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    Before Die Design: Stamped Electrical Terminals DFM Readiness Checklist

    A terminal drawing that passes CAD review but lacks springback compensation data will drift out of tolerance by stroke 50,000. Your supplier catches it only at first-article rejection. This checklist audits flat blank layout, bend radii, and material grain alignment before die steel is cut. Go through every item.

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    Before Tooling Cut: Stamped Electrical Terminals Supplier Audit Checklist

    A missed JESD201 anneal on your terminal lot triggers PPAP rejection, and you catch it only at the compliance audit. This checklist verifies DFM sign-off, material certs, and compliance docs before tooling cut. Go through the full audit.

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    kravzik-high-precision-stamped-electrical-terminals (49)

    Production-Scale Consistency: Appliances Stamped Electrical Terminals Engineering Guide

    A washing machine control board terminal passing factory testing fails after 2,000 cycles when the crimp joint relaxes. In this guide, you will learn cost-optimized material selection and UL 60335 compliance. Read the full guide.

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    kravzik-high-precision-stamped-electrical-terminals (39)

    USCAR-Validated: Automotive Stamped Electrical Terminals Engineering Guide

    An ECU stamped terminal passing testing at 25°C fails after 1,000 thermal shock cycles from -40°C to +125°C. In this guide, you will learn USCAR-2 contact stability and IATF 16949 PPAP. Read the full guide.

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    TECHNICAL REFERENCE

    Frequently Asked Questions

    Answers to common questions regarding precision, tooling, materials, and our integrated molding capabilities.

    We utilize Wire EDM prototyping, high-precision waterjet cutting, 3D printing, and chemical etching to produce functional, production-representative sub-assemblies. Integrated with Siemens NX 3D simulation software, we validate strip layouts, material springback, mechanical fitment, and component interaction in days—preventing costly assembly design revisions before cutting hard steel dies.

    We deliver a comprehensive DFM and assembly feasibility report within 24 hours of receiving your 3D CAD models. Wire EDM or laser-cut assembly prototypes are typically delivered in 3 to 10 business days. Complex multi-station progressive tooling engineered for in-die hardware assembly requires 4 to 8 weeks for complete build, T1 sample submission, and full PPAP Level 3 approval.

    Our multi-station progressive dies achieve tight dimensional tolerances down to ±0.001″ (±0.025 mm) across complex component stacks. Operating on high-speed Minster and Bruderer presses, our active lines feature in-die sensor monitoring and high-resolution camera vision systems to inspect 100% of assembly features, maintaining strict Cpk >= 1.33 / Ppk >= 1.67 quality standards.

    We process micro-to-heavy gage stock from 0.002″ (0.051 mm) to 0.375″ (9.5 mm). Our engineers specialize in multi-material assemblies combining Copper Alloys (Beryllium Copper, Phosphor Bronze, Brass), Stainless Steel, Carbon Steel, Aluminum, and Titanium, as well as pre-plated and selectively-plated bimetal strips optimized for electrical conductivity and corrosion resistance.

    Yes. We specialize in automated in-die joining, replacing expensive secondary manual machining with continuous-strip operations. Capabilities include in-die tapping, automated hardware insertion (nuts, studs, screws, crush bushings), electron beam (EB) welding, and continuous strip overmolding—reducing total program assembly costs by up to 30%.

    You retain 100% ownership of all custom progressive dies and assembly fixtures. We offer guaranteed lifetime die maintenance at no extra cost throughout the active production lifecycle. All die sharpening, component replacement, and preventative refurbishment are executed internally in our fully-equipped tool room.

    Our facility operates under certified IATF 16949 and ISO 9001 quality management systems. Our metrology lab is equipped with Zeiss CMMs, OGP smart optical scopes, and force/displacement test systems to perform First-Article Inspection (FAIR), torque-out/push-out retention testing on inserted hardware, and continuous SPC tracking.

    We operate high-speed automated press fleets ranging from 30 to 90+ tons, achieving speeds up to 1,500 strokes/min (SPM) on specialized press beds up to 57″ x 33″. Our automated facility maintains a monthly throughput capacity exceeding 50 million high-precision stamped components and fully integrated sub-assemblies for global Automotive, EV, Electronics, and Industrial OEMs.

    Still have questions?

    Our engineering team loves solving complex problems. Chat with us or send your drawing for a review.

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